CN109839609B - Method for fuel cell stack voltage sensor diagnostics - Google Patents

Method for fuel cell stack voltage sensor diagnostics Download PDF

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Publication number
CN109839609B
CN109839609B CN201811330093.9A CN201811330093A CN109839609B CN 109839609 B CN109839609 B CN 109839609B CN 201811330093 A CN201811330093 A CN 201811330093A CN 109839609 B CN109839609 B CN 109839609B
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sensor
fuel cell
voltage
cell stack
signal
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CN109839609A (en
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J·J·格力亚朵
A·J·马斯林
J·柏格
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GM Global Technology Operations LLC
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01RMEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/36Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
    • G01R31/382Arrangements for monitoring battery or accumulator variables, e.g. SoC
    • G01R31/3835Arrangements for monitoring battery or accumulator variables, e.g. SoC involving only voltage measurements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60WCONJOINT CONTROL OF VEHICLE SUB-UNITS OF DIFFERENT TYPE OR DIFFERENT FUNCTION; CONTROL SYSTEMS SPECIALLY ADAPTED FOR HYBRID VEHICLES; ROAD VEHICLE DRIVE CONTROL SYSTEMS FOR PURPOSES NOT RELATED TO THE CONTROL OF A PARTICULAR SUB-UNIT
    • B60W10/00Conjoint control of vehicle sub-units of different type or different function
    • B60W10/04Conjoint control of vehicle sub-units of different type or different function including control of propulsion units
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01RMEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/36Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
    • G01R31/396Acquisition or processing of data for testing or for monitoring individual cells or groups of cells within a battery
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/04Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04082Arrangements for control of reactant parameters, e.g. pressure or concentration
    • H01M8/04089Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants
    • H01M8/04119Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants with simultaneous supply or evacuation of electrolyte; Humidifying or dehumidifying
    • H01M8/04156Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants with simultaneous supply or evacuation of electrolyte; Humidifying or dehumidifying with product water removal
    • H01M8/04179Arrangements for control of reactant parameters, e.g. pressure or concentration of gaseous reactants with simultaneous supply or evacuation of electrolyte; Humidifying or dehumidifying with product water removal by purging or increasing flow or pressure of reactants
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/04Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04298Processes for controlling fuel cells or fuel cell systems
    • H01M8/04313Processes for controlling fuel cells or fuel cell systems characterised by the detection or assessment of variables; characterised by the detection or assessment of failure or abnormal function
    • H01M8/0444Concentration; Density
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/04Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04298Processes for controlling fuel cells or fuel cell systems
    • H01M8/04313Processes for controlling fuel cells or fuel cell systems characterised by the detection or assessment of variables; characterised by the detection or assessment of failure or abnormal function
    • H01M8/04537Electric variables
    • H01M8/04544Voltage
    • H01M8/04552Voltage of the individual fuel cell
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/04Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04298Processes for controlling fuel cells or fuel cell systems
    • H01M8/04313Processes for controlling fuel cells or fuel cell systems characterised by the detection or assessment of variables; characterised by the detection or assessment of failure or abnormal function
    • H01M8/04537Electric variables
    • H01M8/04544Voltage
    • H01M8/04559Voltage of fuel cell stacks
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/04Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04298Processes for controlling fuel cells or fuel cell systems
    • H01M8/04313Processes for controlling fuel cells or fuel cell systems characterised by the detection or assessment of variables; characterised by the detection or assessment of failure or abnormal function
    • H01M8/04664Failure or abnormal function
    • H01M8/04686Failure or abnormal function of auxiliary devices, e.g. batteries, capacitors
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/04Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04298Processes for controlling fuel cells or fuel cell systems
    • H01M8/04694Processes for controlling fuel cells or fuel cell systems characterised by variables to be controlled
    • H01M8/04701Temperature
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/04Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04298Processes for controlling fuel cells or fuel cell systems
    • H01M8/04694Processes for controlling fuel cells or fuel cell systems characterised by variables to be controlled
    • H01M8/04746Pressure; Flow
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/04Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04298Processes for controlling fuel cells or fuel cell systems
    • H01M8/04694Processes for controlling fuel cells or fuel cell systems characterised by variables to be controlled
    • H01M8/04858Electric variables
    • H01M8/04865Voltage
    • H01M8/0488Voltage of fuel cell stacks
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/04Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04298Processes for controlling fuel cells or fuel cell systems
    • H01M8/04694Processes for controlling fuel cells or fuel cell systems characterised by variables to be controlled
    • H01M8/04858Electric variables
    • H01M8/04925Power, energy, capacity or load
    • H01M8/0494Power, energy, capacity or load of fuel cell stacks
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01RMEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R35/00Testing or calibrating of apparatus covered by the other groups of this subclass
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01RMEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R35/00Testing or calibrating of apparatus covered by the other groups of this subclass
    • G01R35/005Calibrating; Standards or reference devices, e.g. voltage or resistance standards, "golden" references
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2250/00Fuel cells for particular applications; Specific features of fuel cell system
    • H01M2250/20Fuel cells in motive systems, e.g. vehicle, ship, plane
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30Hydrogen technology
    • Y02E60/50Fuel cells
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/40Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

A method of evaluating voltage sensor output using a diagnostic system includes: determining a total voltage of the fuel cell stack using a stack voltage sensor; identifying a fuel cell voltage of the first end cell using the first end cell voltage sensor and identifying a fuel cell voltage of the second end cell using the second end cell voltage sensor; determining whether a maximum of a total voltage of the fuel cell stack, a fuel cell voltage of the first end cell, or a fuel cell voltage of the second end cell is less than a sensor limit, and whether a minimum of the fuel cell voltages is greater than the sensor limit; performing a test to identify whether the maximum value is greater than the average value of the sensor signals and whether the average value of the sensor signals is greater than the minimum value; a test is performed to identify if the minimum value is less than a first predetermined threshold.

Description

Method for fuel cell stack voltage sensor diagnostics
Introduction to the design reside in
The present disclosure relates to a system and method for monitoring hydrogen fuel cell stack voltage.
In existing vehicular hydrogen fuel cells and fuel cell stacks, at least one voltage sensor is used for every other fuel cell in the stack, or a dedicated voltage sensor is provided for determining the voltage potential of each fuel cell in the fuel cell stack. The number of voltage sensors is large, thus making the cost high. It is currently believed that reducing the number of voltage sensors reduces the number of sampling points used to identify whether sensor drift is occurring or sensor failure has occurred, thereby reducing the quality of the sampling points.
Currently, a false sensor reading may be interpreted as an electrochemical phenomenon, and such a sensor reading may not be immediately recognized as a false. Due to the electrochemical processes within the fuel cell stack, there is currently no known method to identify a faulty sensor whose output is within a viable reading range. When a fuel cell is actually experiencing a problem, the faulty cell within the fuel cell stack is not identified because the reading of the faulty cell sensor can be displayed as a normal state.
Thus, while existing stack voltage sensor systems have achieved their intended purpose, there remains a need for new and improved systems and methods for determining the state of a fuel cell stack using a stack voltage sensor system.
Disclosure of Invention
According to several aspects, a method of evaluating a voltage sensor output using a fuel cell stack voltage sensor diagnostic system includes: in a first stage of rationality testing, determining whether a maximum value of a fuel cell voltage sensor signal of the fuel cell stack is less than a sensor limit and whether a minimum value of the sensor signal is greater than the sensor limit; performing a second level of rationality test to identify whether the maximum value of the sensor signal is greater than the average value of the sensor signal and whether the average value of the sensor signal is greater than the minimum value of the sensor signal; and a third level of rationality test is conducted to identify whether the minimum value of the sensor signal is less than a first predetermined threshold.
In another aspect of the disclosure, the method comprises: if the minimum value of the sensor signal is less than a first predetermined threshold, power to the system is observed to identify whether the fuel cell stack is operating in a low power mode.
In another aspect of the disclosure, the method comprises: if a negative response is generated to the low power observation, a time request is made wherein the determined time of operation at low power is compared to a predetermined minimum time.
In another aspect of the disclosure, the method comprises: if a negative response is generated to the low power observation and a predetermined time limit has been reached indicating that the fuel cell stack has been operating at high power for more than a predetermined minimum time, a low power request is sent to the vehicle system controller.
In another aspect of the present disclosure, the method includes sending a request to a vehicle system controller to perform an increase reactant concentration test; when enabled by the vehicle system controller, an increase reactant concentration test is performed, including increasing at least one of system pressure, system temperature, and system flow, to remove liquid water from the fuel cell stack.
In another aspect of the disclosure, the method includes performing a re-analysis of the fuel cell voltage sensor signal in a first comparison test to identify whether a minimum value of the sensor signal is less than a second predetermined threshold, the second predetermined threshold being at least equal to or higher than the first predetermined threshold.
In another aspect of the disclosure, the method includes submitting an open circuit voltage request to a vehicle system controller.
In another aspect of the disclosure, the method comprises: performing a reanalysis of the fuel cell voltage sensor signal after the open circuit voltage request is granted and comparing, in a second comparison test, a minimum value of the sensor signal with a third predetermined threshold value, the third predetermined threshold value being at least equal to or higher than the second predetermined threshold value; and evaluate whether any other diagnostic faults are present.
In another aspect of the disclosure, the method comprises: if the maximum value of the sensor signal is greater than the sensor limit or the minimum value of the sensor signal is less than the sensor limit, a battery determination failure warning is generated.
In another aspect of the disclosure, the method comprises: if the maximum value of the sensor signal is greater than the average value of the sensor signal or the average value of the sensor signal is less than the minimum value of the sensor signal, a battery measurement failure warning is generated.
According to several aspects, a method of evaluating a voltage sensor output using a fuel cell stack voltage sensor diagnostic system includes: determining a total voltage of the fuel cell stack using a fuel cell stack voltage sensor; in a first stage rationality test, determining whether the maximum value of the total voltage of the fuel cell stack is less than a sensor limit and whether the minimum value of the total voltage of the fuel cell stack is greater than the sensor limit; performing a second level of rationality test to identify whether the maximum value is greater than the average value of the sensor signals and whether the average value of the sensor signals is greater than the minimum value; a third level of rationality testing is conducted to identify whether the minimum value is less than a first predetermined threshold.
In another aspect of the disclosure, the method comprises: if the minimum value is less than a first predetermined threshold, initiating a power request to a vehicle system controller to identify whether the fuel cell stack is operating in a low power mode; if a positive response is generated to the power request indicating that the fuel cell stack has been operating at low power for more than a predetermined minimum time, a low power request is sent to the vehicle system controller.
In another aspect of the disclosure, the method includes sending a request to a vehicle system controller to perform an increase reactant concentration test after confirming that the time that the fuel cell stack is operating at low power has exceeded a predetermined minimum time.
In another aspect of the disclosure, the method comprises: when enabled by the vehicle system controller, performing an increase reactant concentration test comprising increasing at least one of system pressure, system temperature, and system flow to remove liquid water from the fuel cell stack; the steps of determining and identifying are repeated.
In another aspect of the disclosure, the method includes performing a re-analysis of the total voltage of the fuel cell stack, the fuel cell voltage of the first end cell, or the fuel cell voltage of the second end cell in a first comparative test.
In another aspect of the disclosure, the method comprises: submitting an open circuit voltage request to a vehicle system controller if the minimum value is less than a second predetermined threshold (the second predetermined threshold being at least equal to or higher than the first predetermined threshold); after the request for the open circuit voltage is granted, a re-analysis of the total voltage of the fuel cell stack, the fuel cell voltage of the first end cell or the fuel cell voltage of the second end cell is performed and in a second comparison test the minimum value is compared with a third predetermined threshold value, which is at least equal to or higher than the second predetermined threshold value.
In another aspect of the disclosure, the method comprises: if the minimum value is less than a third predetermined threshold, a fuel cell stack short circuit analysis is performed.
According to several aspects, a method of evaluating a voltage sensor output using a fuel cell stack voltage sensor diagnostic system includes: measuring a total voltage of the fuel cell stack using a fuel cell stack voltage sensor; identifying a fuel cell voltage for each of a first end cell of the fuel cell stack using a first end cell voltage sensor and a fuel cell voltage for each of a second end cell of the fuel cell stack using a second end cell voltage sensor; in a first level rationality test, determining whether a maximum of a total voltage of the fuel cell stack, a fuel cell voltage of the first end cell, or a fuel cell voltage of the second end cell is less than a sensor limit, and whether a minimum of the total voltage of the fuel cell stack, the fuel cell voltage of the first end cell, or the fuel cell voltage of the second end cell is greater than the sensor limit; performing a second level of rationality test to identify whether the maximum value is greater than the average value of the sensor signals and whether the average value of the sensor signals is greater than the minimum value; performing a third level of rationality test to identify whether the minimum value is less than a first predetermined threshold; if the minimum value is less than a first predetermined threshold, initiating a power request to a vehicle system controller to identify whether the fuel cell stack is operating in a low power mode; after confirming that the fuel cell stack is operating in the low power state for more than a predetermined minimum time, a request to perform an increase reactant concentration test is sent to a vehicle system controller.
In another aspect of the disclosure, the method includes determining fuel cell voltage values for a plurality of characteristics of the fuel cell stack that vary between a range of-1.5 potentiometric volts direct current to +1.5 potentiometric volts direct current, the cell voltage values including voltage ranges indicative of cathode-oxygen evolution, cathode carbon corrosion, cathode ECSA loss, normal operating range, cathode starvation, anode-platinum-oxide growth, anode carbon corrosion, and anode oxygen evolution.
In another aspect of the disclosure, the method comprises: performing a re-analysis of the total voltage of the fuel cell stack, the fuel cell voltage of the first end cell or the fuel cell voltage of the second end cell; submitting an open circuit voltage request to a vehicle system controller if the minimum value is less than a second predetermined threshold (the second predetermined threshold being at least equal to or higher than the first predetermined threshold); requesting an open circuit voltage state; a re-analysis of the total voltage of the fuel cell stack, the fuel cell voltage of the first end cell or the fuel cell voltage of the second end cell is performed and the minimum value is compared in a second comparison test with a third predetermined threshold value, which is at least equal to or higher than the second predetermined threshold value.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
Drawings
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
FIG. 1 is a front perspective view of a fuel cell stack according to an exemplary embodiment;
FIG. 2 is a diagrammatical representation of a fuel cell stack voltage sensor diagnostic system in accordance with an exemplary embodiment;
FIG. 3 is a diagrammatic view of a portion of the system shown in FIG. 2; and
fig. 4 is a graph of voltage potential versus current in the fuel cell stack voltage sensor diagnostic system of the present disclosure.
Detailed Description
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
Referring to fig. 1, a fuel cell stack voltage sensor diagnostic system 10 provides diagnostic information for an exemplary fuel cell stack 12, and the fuel cell stack 12 may include a plurality of individual fuel cells 14. According to several aspects, the fuel cell stack voltage sensor diagnostic system 10 includes at least one total stack voltage sensor 16, and the total stack voltage sensor 16 may be used to obtain a total stack voltage. According to further aspects, the fuel cell stack voltage sensor diagnostic system 10 may include, in addition to the total stack voltage sensor 16, a voltage sensor dedicated to obtaining the cell voltage of each of the opposing end cells of the fuel cell stack 12. The voltage of the first end battery 18 may be obtained using a dedicated first end battery sensor 20. Similarly, the voltage of the second end cell 22 may be obtained using a dedicated second end cell sensor 24. End cell data is useful because the end cell typically operates at the highest temperature limit of the fuel cell stack and may also identify whether conditions such as cell flooding, hydrogen starvation, or other similar operating conditions may occur.
Referring to fig. 2 and again to fig. 1, the stack voltage sensor diagnostic system 10 adds data from the graph 26 to an algorithm 28 and uses the algorithm 28 to distinguish the sensed voltage condition of the fuel cell stack 12 shown with reference to fig. 1 or individual fuel cells 14 of the fuel cell stack 12 from sensor errors, the individual fuel cells 14 representing physical phenomena aligned with the physical characteristics of the fuel cell stack 12. Examples of sensor errors may include sensor drift and sensed conditions that may be within expected conditions of the fuel cell, but the sensed conditions may be errors or fuel cell problems.
In the graph 26, an ordinate 29 represents typical fuel cell voltage values varying between-1.5 volts dc to +1.5 volts dc, and an abscissa 30 represents a plurality of measured or measurable characteristics of the fuel cell stack 12. These characteristics may include a range of cathode-oxygen evolution reaction values 32, cathode carbon corrosion values 34, cathode-ECSA loss values 36, normal operating values 38, cathode starvation values 40, anode-platinum-oxide values 42, anode-carbon corrosion values 44, and anode-oxygen evolution reaction values 46.
The depicted sensor normal measurement range curve 48 covers values of the sensor measurement range 50 between approximately-1.0 VDC and +1.0 VDC. Characteristic values, such as cathodic-oxygen evolution reaction value 32, which typically range from about +1.4 to +1.5VDC, are considered to be outside of the normal sensor measurement range 50 at the time of sensing and are therefore considered to be significant sensor failures. Characteristic values, such as anode-carbon corrosion value 44, which typically vary between about-0.5 VDC to-1.5 VDC, overlap the sensor measurement range 50, so that a signal indicative of anode-carbon corrosion value 44 may not be readily identified as a stack fault or a normal measurement range. The characteristic value, such as cathode starvation value 40, is typically well within the normal sensor sensing range 50 of the voltage sensor, so if a sensor drift or similar sensor failure occurs, the sensor value identifying cathode starvation value 40 will typically not identify whether a fuel cell problem or a fuel cell stack problem exists. It is clear that different methods are required to distinguish between stack faults and normal measurement range problems. An algorithm 28 is provided for distinguishing between stack fault problems and normal measurement range problems.
In a first step 52, the algorithm 28 receives the sensor signal and in a second step 54, a diagnostic analysis is initiated by initially conducting a three (3) level rationality test for the sensor signal. In a first or I-stage rationality test 56, it is determined whether the maximum value of the sensor signal is less than the sensor limit and whether the minimum value of the sensor signal is greater than the sensor limit. If the maximum value of the sensor signal is greater than the sensor limit or the minimum value of the sensor signal is less than the sensor limit, then the sensor is deemed to be not malfunctioning, but a battery determination failure warning 58 is generated, for which predetermined remedial action may be taken.
If the maximum value of the sensor signal is less than the sensor limit or the minimum value of the sensor signal is greater than the sensor limit, a second or class II rationality test 60 is conducted. In a level II rationality test 60, it is determined whether the maximum value of the sensor signal is greater than the average value of the sensor signal and whether the average value of the sensor signal is greater than the minimum value of the sensor signal. If the maximum value of the sensor signal is greater than the average value of the sensor signal, or the average value of the sensor signal is less than the minimum value of the sensor signal, then the sensor is deemed to be not malfunctioning, but a battery determination failure warning 58 is generated, for which predetermined remedial action may be taken.
Failure of the level I rationality test 56 or the level II rationality test 60 to indicate a sensor fault or failure may be caused by, for example, a single cell short or a stack short. Individual cell shorts or stack shorts can be identified using separate tests outside the scope of this disclosure.
If the results of both the level I rationality test 56 and the level II rationality test 60 indicate that the voltage sensor value is within the range of the voltage sensor or the average output signal of the voltage sensor, a level III rationality test 62 is conducted, as described in more detail with reference to FIG. 3. A level III rationality test 62 may be used to indicate a sensor fault. If a sensor fault is indicated at the end of the analysis using algorithm 28, then a diagnostic fault is indicated 64.
Referring to fig. 3 and again to fig. 1 and 2, the algorithm 28 uses the following operational steps. If the level I rationality test 56 fails, a fail signal 66 is transmitted to generate the battery determination failure warning 58. If the level I rationality test 56 passes, a pass signal 68 is transmitted to initiate the level II rationality test 60. If the level II rationality test 60 fails, a fail signal 70 is transmitted to generate the battery determination failure warning 58. If the level II rationality test 60 passes, a pass signal 72 is transmitted to initiate the level III rationality test 62.
During the level III rationality test 62, it is determined whether the minimum value of the sensor signal is less than a first predetermined threshold 74. The first predetermined threshold 74 is based on system defined criteria, such as averaging a plurality of measured fuel cell stack characteristics, and may be adaptive on a continuous stack and cell health monitoring basis. The first predetermined threshold 74 is selected to minimize false positives. If the minimum value of the sensor signal is not less than the first predetermined threshold 74, a restart signal 76 is generated to return the algorithm 28 to the second step 54 to restart the diagnostic analysis. If the minimum value of the sensor signal is less than the first predetermined threshold 74, the enable signal 78 initiates a power request 80, by which it is determined whether the fuel cell stack 12 is operating in a low power mode, such as at or below about 5kw of power, by the power request 80.
If a negative response 82 is generated to the power request 80, a time request step 84 is performed. At time request step 84, the time of low power operation is compared to a predetermined minimum time. If the low power operation is not for more than the predetermined minimum time, a loop back 86 is made to restart the power request 80. The loop back 86 is performed because in the subsequent portion of the algorithm 28, it is advantageous to perform further signal testing only at low stack power operation, and repeating the time request step 84 allows the fuel cell stack 12 to be normalized at low power.
If a positive response 88 is generated to the power request 80 and the fuel cell stack 12 has thus been operating at low power for more than a predetermined minimum time, a low power request 90 is sent to the vehicle system controller 91 to identify a request to conduct an increased reactant concentration test 92 at the electrodes of the fuel cell stack 12 when permitted and feasible, such as when the vehicle operator does not request high power or high speed operation. When the vehicle system controller 91 permits, the increase reactant concentration test 92 will confirm whether a low battery condition exists, which evaluation must be run at low power. The increase reactant concentration test 92 will temporarily ensure that mass transport or parasitic current related effects are temporarily minimized by removing excess water that may accumulate in the fuel cell 14 or by increasing the reactant concentration (increasing hydrogen and oxygen supply) to temporarily ensure that a known reactant concentration is present. For example, water may be removed from the fuel cell by increasing the cell pressure, increasing the cell flow rate, and/or increasing the cell temperature to a predetermined period of time.
These conditions cannot be set when the fuel cell stack 12 may need to deliver power above a low power level, and are preferably established when the fuel cell stack power demand is substantially zero. Thus, the vehicle system controller 91 will receive the low power request 90 and grant the request according to the system performance requirements, or place the request in a hold state before the system reaches the required power level. It should also be noted that if the response from the power request 80 is that the fuel cell stack 12 is operating in a low power mode, the time request step 84 is bypassed and the increase reactant concentration test 92 may be immediately performed.
The fuel cell stack 12 is preferably at low power so that it operates in the dynamic region of the power curve where the actual or measured performance of the fuel cell stack 12 is closest to ideal. It also allows for tests to be performed that do not affect the expected changes or demands of the driver in the low power state. The physical properties of the electrochemical potential at low power are not affected by kinetic energy loss, resistive loss, ion loss, or fuel reaction loss. The operator is not able to sense when the increase reactant concentration test 92 is performed at low power.
After performing the increase reactant concentration test 92, the output signals from the stack voltage sensors (e.g., the stack total voltage sensor 16, the dedicated first end cell sensor 20, and the dedicated second end cell sensor 24) are again analyzed to determine whether stack conditions, such as flooding, have been cleared or whether these stack conditions have not affected the sensor readings. The pressure sensor readings are also used to confirm the presence or absence of flooding of the battery channels. In a first comparison test 96, the minimum output value of the sensor is compared with a second predetermined threshold 98. The second predetermined threshold 98 is at least equal to or greater than the first predetermined threshold 74 because cell flooding in the fuel cell stack 12 is expected to have cleared and a higher fuel concentration has been supplied to the fuel cells, and thus a higher cell voltage is expected to be measured. Pressure and voltage baselines are determined from predetermined data in the data table based on the current power range for predicting an expected output voltage to compare with the new voltage output received from the voltage sensor.
If the minimum voltage is greater than the second predetermined threshold 98, a negative response 100 is generated to return the system to the second step 54, where the diagnostic analysis is restarted. A negative response 100 indicates that the fuel cell is no longer at a low potential due to a fault condition such as flooding or improper fuel concentration, and therefore, the correctable cell problem is corrected, the sensor is not faulty, and the diagnostic can be restarted.
With the fuel cell stack 12 still operating at low power, if the minimum voltage is less than the second predetermined threshold 98, a positive response 102 is generated, thereby generating an open circuit voltage request 104, and transmitting the open circuit voltage request 104 to the vehicle system controller 91. The vehicle system controller 91 receives the open circuit voltage request 104 and either grants the request if the vehicle operating conditions permit, or places the request in a reserved state. The open circuit voltage request 104 commands the system boost converter to draw zero power from the fuel cell stack 12 while the reactants are still being fed into the fuel cell stack 12. The stack maximum potential should therefore occur near the theoretical cell voltage limit of the fuel cell stack 12.
After the open circuit voltage request is granted 104, the sensor voltage is re-measured and re-analyzed. In a second comparison test 106, the minimum output value of the sensor is compared with a third predetermined threshold 108. The third predetermined threshold 108 is at least equal to or greater than the second predetermined threshold 98 because the fuel cell stack 12 is expected to be producing its maximum cell voltage. If the minimum sensor voltage is greater than the third predetermined threshold 108, a negative response 110 is generated to return the system to the second step 54, where the diagnostic analysis is restarted. A negative response 110 indicates that the fuel cell is operating as expected, so the sensor is not malfunctioning, and the diagnostic can resume.
With the fuel cell stack 12 still operating in accordance with the open circuit voltage request 104, if the minimum voltage is less than the third predetermined threshold 108, a positive response 112 is generated and other active diagnostic requests 114 are made to determine if certain other diagnostic tests indicate a different fuel cell stack problem, such as a stack short or a cell short. If the response to the other activity diagnostic request 114 is negative 116, a battery measurement failure alert 58 is generated, for which predetermined remedial action may be taken. If the response to the other active diagnostic request 114 is affirmative 118, a diagnostic fault 64 is indicated.
Referring to fig. 4 and again to fig. 3, the current-potential diagram 120 presents a different range of cell potentials 122 over a range of cell currents 124 for the hydrogen fuel cell stack 12. The cell potential loss is caused by the activation overpotential, resulting in a cell potential voltage range 126 at very low cell currents. A falling cell potential voltage 128 due to ohmic losses is generated in the intermediate cell current range. The mass transfer loss causes the battery potential voltage 130 to reach substantially zero at a maximum battery current of 1.0 amp. As previously described, the open circuit voltage request 104 may be made in order to eliminate the effects of mass transfer loss, ohmic loss, and kinetic energy loss when determining whether the voltage sensor is operating properly. When the open circuit voltage request 104 commands the system boost converter to draw zero power from the fuel cell stack 12 while reactants are still being fed into the fuel cell stack 12, the maximum potential voltage 132 of the fuel cell stack 12 is reached at the high cell potential voltage 134. The battery potential voltage 134 may then be used as a reference voltage to be compared to the actual output of the voltage sensor.
The fuel cell stack voltage sensor diagnostic system 10 of the present disclosure has several advantages. The fuel cell stack voltage sensor diagnostic system 10 provides a multi-step approach to sequentially eliminate various fuel cell problems that may cause voltage sensor output differences. Multiple retesting of the voltage sensor output using different predetermined thresholds increases the level of assurance that no sensor failure has occurred before determining a system sensor failure. Thus, the fuel cell stack voltage sensor diagnostic system 10 applying the algorithm 28 improves the confidence that a reduced number of system voltage sensors will accurately provide the fuel cell stack voltage potential.
The description of the disclosure is merely exemplary in nature and variations that do not depart from the gist of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.

Claims (8)

1. A method of evaluating a voltage sensor output using a fuel cell stack voltage sensor diagnostic system, comprising:
determining in a first stage rationality test whether a maximum value of a fuel cell voltage sensor signal of the fuel cell stack is less than a sensor limit and a minimum value of said sensor signal is greater than said sensor limit, and if the maximum value of the sensor signal is greater than the sensor limit or the minimum value of said sensor signal is less than the sensor limit, deeming that the sensor is not faulty, but generating a battery determination failure warning;
if the maximum value of the sensor signal is less than the sensor limit or the minimum value of the sensor signal is greater than the sensor limit, performing a second level of rationality testing to identify if the maximum value of the sensor signal is greater than the average value of the sensor signal and if the average value of the sensor signal is greater than the minimum value of the sensor signal, and if the maximum value of the sensor signal is greater than the average value of the sensor signal or the average value of the sensor signal is less than the minimum value of the sensor signal, deeming the sensor to be free of faults, but generating a battery determination failure warning; and is
If the results of the first and second level rationality tests both indicate that the voltage sensor value is within the range of the voltage sensor or the average output signal of the voltage sensor, then performing a third level rationality test to identify if the minimum value of the sensor signal is less than a first predetermined threshold, further comprising sending a power request to a vehicle system controller to identify if the fuel cell stack is operating in a low power mode if the minimum value of the sensor signal is less than the first predetermined threshold,
wherein the presence of a diagnostic fault is indicated if a sensor fault is indicated at the end of the analysis using the following operational steps: transmitting a failure signal to generate a battery determination failure warning if the first level of rationality test fails; if the first level of rationality testing passes, transmitting a pass signal to initiate a second level of rationality testing; transmitting a failure signal to generate a battery determination failure warning if the second level rationality test fails; if the second level rationality test passes, a pass signal is transmitted to initiate a third level rationality test.
2. The method of evaluating voltage sensor output using a fuel cell stack voltage sensor diagnostic system of claim 1, further comprising: if a negative response is generated to the power request, a time request is made, wherein the time determined under low power operation is compared to a predetermined time.
3. The method of evaluating voltage sensor output using a fuel cell stack voltage sensor diagnostic system of claim 1, further comprising: sending a low power request to the vehicle system controller if a negative response is generated to the low power request indicating that the fuel cell stack has been operating at high power for more than the predetermined time.
4. The method of evaluating voltage sensor output using a fuel cell stack voltage sensor diagnostic system of claim 3, further comprising:
sending a request to the vehicle system controller to perform an increase reactant concentration test; and is
When enabled by the vehicle system controller, performing the increased reactant concentration test including increasing at least one of system pressure, system temperature, and system flow to remove liquid water from the fuel cell stack.
5. The method of evaluating voltage sensor output using a fuel cell stack voltage sensor diagnostic system of claim 4 further comprising performing a re-analysis of the fuel cell voltage sensor signal in a first comparison test to identify if a minimum value of the sensor signal is less than a second predetermined threshold that is at least equal to or higher than the first predetermined threshold.
6. The method of evaluating voltage sensor output using a fuel cell stack voltage sensor diagnostic system of claim 5, further comprising submitting an open circuit voltage request to the vehicle system controller.
7. The method of evaluating voltage sensor output using a fuel cell stack voltage sensor diagnostic system of claim 6, further comprising:
performing a re-analysis of the fuel cell voltage sensor signal after the open circuit voltage request is granted, and in a second comparison test, comparing a minimum value of the sensor signal with a third predetermined threshold value, the third predetermined threshold value being at least equal to or higher than the second predetermined threshold value; and is
It is evaluated whether there are any other diagnostic faults.
8. A method of evaluating a voltage sensor output using a fuel cell stack voltage sensor diagnostic system, comprising:
determining a total voltage of the fuel cell stack using a fuel cell stack voltage sensor;
identifying a fuel cell voltage for each of a first end cell of the fuel cell stack using a first end cell voltage sensor and a fuel cell voltage for each of a second end cell of the fuel cell stack using a second end cell voltage sensor;
in a first stage rationality test, determining whether the maximum of the total voltage of the fuel cell stack, the fuel cell voltage of the first end cell or the fuel cell voltage of the second end cell is less than a sensor limit and whether the minimum of the total voltage of the fuel cell stack, the fuel cell voltage of the first end cell or the fuel cell voltage of the second end cell is greater than the sensor limit, if the maximum of the sensor signal is greater than the sensor limit or the minimum of the sensor signal is less than the sensor limit, the sensor is considered to be not faulty but a cell determination failure warning is generated;
if the maximum value of the sensor signal is less than the sensor limit or the minimum value of the sensor signal is greater than the sensor limit, performing a second level of rationality testing to identify if the maximum value is greater than the average value of the sensor signal and if the average value of the sensor signal is greater than the minimum value, and if the maximum value of the sensor signal is greater than the average value of the sensor signal or the average value of the sensor signal is less than the minimum value of the sensor signal, deeming the sensor to be free of faults, but generating a battery determination failure warning;
if the results of both the first and second level rationality tests indicate that the voltage sensor value is within the range of the voltage sensor or the average output signal of the voltage sensor, a third level rationality test is conducted to identify if the minimum value is less than a first predetermined threshold,
wherein the presence of a diagnostic fault is indicated if a sensor fault is indicated at the end of the analysis using the following operational steps: transmitting a failure signal to generate a battery determination failure warning if the first level of rationality test fails; if the first level of rationality testing passes, transmitting a pass signal to initiate a second level of rationality testing; transmitting a failure signal to generate a battery determination failure warning if the second level rationality test fails; if the second level rationality test passes, transmitting a pass signal to initiate a third level rationality test;
if the minimum value is less than the first predetermined threshold, initiating a power request to a vehicle system controller to identify whether the fuel cell stack is operating in a low power mode; and is
After confirming that the time that the fuel cell stack is operating in the low power mode has exceeded the predetermined minimum time, sending a request to the vehicle system controller to perform an increase reactant concentration test.
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